I'm looking on www.horsepowerfreaks.com and they have a borla cat back on clearance for 325. It only lists the years 92-95. Does anyone know the difference between the exhaust on a 95 and 96?

 

Yes, the 96 has a double cat back system. It also has the obdII computer. Some 95 broncos also have this setup. The double cat sucks because it is hard to put on complete performance exhaust expecialy if you have emision checks in your city. I bought a high flow cat and could not use it. I was told I might not pass the emision check.

 

But, won't the system be the same after the converters? Or no? Do you know anyone that makes a system for the 96? Even Bassani lumps the 96 in with the other 90's models.

 

Yup, in the 1996 model year 5.0L engine Ford decided to be different. They put the O2 Sensor bung in the exhaust manifold instead of the Y pipe. This was the only year and the only engine that Ford did this to, so many (OK, most) aftermarket exhaust people ingore the 96 5.0L. They say that due to the limited application, it is just not cost effective (true) to build a product line that only fits on 96 5.0L Broncos.
Thanks Ford, appreciate that one. Oh well, I still love my Bronco.

As far as the cat-back goes, there is absolutely no difference between a 95 and 96. Some manufacturers believe that 95 was the last year that Ford made the Bronco. Got into a e-mail debate with MSD tech support when I asked why there was no billet distributor application for a 96 5.0L. Tech support insisted that there was no such thing as a 1996 Ford Bronco with a 5.0L engine. Went on to say that he was "absolutely certain" that Ford stopped making the Bronco in 1995. Sent him digital photos of truck, VIN plate, and the door frame sticker. Scanned the cover of the owners manual, and window sticker. Sent all this to him and his supervisor. Got HUGE apology and a part number...no discount...but an apology.

If you are looking for something specific, let me know. I may know where to find it. Been scrounging for 96 aftermarket parts for three years.

Good Luck

 

Bronco Cam, most of the EFI Broncos use the double cat system. The first cat is where the system comes together (the Y) and the second cat is about a foot back. The big difference in 95-96 is that Ford put a third O2 sensor (OBD II) just behind the first cat. There is no reason why you cannot install a high flow cat in the second position. Been there done that, and I live in Connecticut, where the tree police reign supreme. No problem with emissions, passed with flying colors. You just have to cut the system just behind the inlet tube from the air pump.

Bassani makes a complete performance Y pipe and cat system for the 5.8 in this configuration, the only reason they do not make one for the 5.0 in 96 is because of the O2 bung being in the manifold instead of the pipe. Same old limited application story. From the air pipe back the systems are identical with the older ones.

 

Well, mine is the 5.8 so I guess I would be OK to order the borla cat back, right? As for something specific, I've looked at Bassani but thats a little more than I want to spend. Any other recommendations?

 

Bassani is the only one that makes the whole replacement Y pipe in a performance configuration. You can buy a high flow cat at summit, jegs, or anyplace that sells performance exhaust. Buy a 3"in 3" out high flow cat without the air pipe. You can cut the exhaust about an inch or two behind where the pipe from the air pump mates with the exhaust, and have your exhaust guy weld the performance cat in there (unless, of course, you have a welder).

If you are going to buy an aftermarket cat back system, then you have many choices. I originally had a flowmaster force II. Gibson, Borla, Bassani, Summit, Magnaflow, etc... all make cat back systems for the 90's broncos. If it will fit a 94 or a 95, it will fit a 96. A single 3" cat-back is a good choice, the source dependent upon how much you want to spend.

As I said, I originally had the flowmaster force II, but I wanted dual outlets and a more aggressive tone, so I dumped the flowmaster and went custom.

I have a Magnaflow 3in 3out high flow cat, Magnaflow single 3" inlet, dual 2.5" outlet muffler, and twin pipes exiting behind the passenger rear wheel. 3" slant cut stainless tips. Looks great, sound better, performs great.

If I had a 5.8 I would wait until I could afford the Bassani Y pipe system. You can get by cheaper, but you get what you pay for.

Good Luck.

 

Thanks big red, I will install a high flow cat. I took my truck to three different muffler shops in Portland Oregon. Not one of them would install a high flow cat. All of them told me it was do to the year 1996 and the duel cat set up. They said I would have nothing but problems with my oxygen sensors. The funny thing is my buddy on the coast has the same bronco 1996 with a 351 and he had a high flow cat put in and did not have any problems.

 

I have another question. If I have a 1996 why do I not have a air pump? Would not the airpump be run by the fan belt? I do not have one, and nothing has been removed

 

On the 96 your air pump should be on the passenger side just below the alternator. Yes it is driven by the serpentine belt. If you did not buy the truck brand new, there is the possibility that someone installed a air pump delete kit. Replaces the pump with an idler pulley. If purchased as a kit, and properly installed, the end product looks like the truck was built that way.
If your air pump was deleted and you have not yet fallen victim to the tree police, no problem. If your state is discussing implementing an emissions program, you could have problems on the horizon.
Be interested to know what you find, as all 1996 Broncos built in the US included air pumps. Check your VIN to see where it was built.

Good Luck.

 

This is getting interesting. I passed my state emissions test. Where the air pump should be there is a large pully that is attached to a cast braket that is bolted to my engine. It even has a factory ford stamp on it. But there are not any hoses wires etc coming from it. I know what a ford airpump looks like and this looks nothing like it. What do you think?

 

Hmmmmm....
Did you buy the truck new?
Where does VIN show as manufacture location?
Have you looked at section of exhaust between the two cats to see if the air inlet tube is there or has been modified?

It is possible to pass emissions without the air pump if the truck is in good shape. The air pump injects fresh air into the second cat to assist in the removal of unburned hydrocarbons. An engine in good shape can easily fall within emissions limits even without a cat. Many have done it. Some have hollowed out their cats in order to get by those emission tests that include a visual inspection. Not advisable, but it works.

I am going to do some digging on this end, but sounds like smog pump was deleted. Could be wrong.

Very interesting.

 

try www.truckperformance.com you just put vehicle make, model, and year

 

My 96 only has IDLER pulley and no air pump as far as I can tell also. It is a 96 XLT Sport with 5.8 I always see people mention the air pump and have not found mine yet. My brother has a 92 and the whole setup on the passenger side of the mototr is different no parts that can be interchanged between the two. I was going to look at his IDLER pulley to see if mine needed replaced and it was totally different. 96 and 95 with California Emissions are the only ones with MAF and OBD II set ups. parts are available but you have to do a little looking.

 

Actually all vehicles manufactured in the United States were required to have OBD II beginning with the 1996 model year. Some manufacturers, Ford included, started putting it on some models in 1995 to gear up for the federal requirement which they knew was coming.
As far as some not having the air pump on the 5.8, I am looking in to that one. I e-mailed Ford tech support (member of their program) and they responded with the following:

"All 5.0L Ford engines manufactured after 1994 included a smog (air injection) pump if the vehicle was manufactured in the United States. The only exception to this were vehicles designed and built for export."

In my original e-mail I had asked about both the 5.0 and the 5.8, but they obviously neglected to address the 5.8. I e-mailed them again and await the response.

Curiouser and curioser.